Connector Sealing with Rubber Plug and Potting Agent
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Solution Overview
Problem
Existing connectors fail to completely prevent foreign matter intrusion due to gaps between fitting surfaces, particularly around lock holes, leading to potential short circuits and increased size requirements for additional sealing measures.
Innovation Solution
A connector design featuring a first housing with a terminal accommodating portion and a second housing with an annular receptacle, where a rubber plug and potting agent are used to seal gaps between the housings, eliminating the need for lock holes and reducing size by using press-fit projections and recesses for connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a rubber ring is added between the housings to prevent foreign matter intrusion, then foreign matter prevention is improved, but the connector size increases in both fitting direction and radial direction
Solution Approach 1:
The patent uses a rubber plug (flexible material) to seal the terminal accommodating portion, preventing foreign matter intrusion without requiring additional space. The rubber plug is accommodated inside a recessed portion that projects rearward from the rear surface, utilizing existing structural space rather than adding external volume.
Solution Approach 2:
The rubber plug is nested within the terminal accommodating portion structure, specifically accommodated inside the recessed portion. This nesting approach allows the sealing element to be integrated into the existing housing structure without increasing overall connector dimensions.
2Reliability
If lock holes are provided in the receptacle for locking mechanism, then connection reliability is improved, but foreign matter can intrude through the lock holes
Solution Approach 1:
The patent removes the lock holes from the receptacle structure entirely. Instead of having through-holes for locking, the design uses a press-fit mechanism where the terminal accommodating portion is pressed into the receptacle, eliminating the opening that would allow foreign matter intrusion while maintaining connection reliability.
Solution Approach 2:
The patent introduces a rubber plug as an intermediary sealing element that fills the terminal accommodating portion. This rubber plug acts as a mediator that prevents foreign matter from entering through any potential openings while allowing the press-fit locking mechanism to function.
3Object-affected harmful factors
If foreign matter intrusion preventing protrusions and recesses are added to extend creepage distance, then foreign matter prevention is improved, but device complexity increases
Solution Approach 1:
The patent uses a simple rubber plug to seal the terminal accommodating portion, replacing the complex labyrinth structure of protrusions and recesses. The flexible rubber material provides effective sealing through its inherent properties without requiring additional geometric complexity.
Data Source
AI summary
A connector (relay connector 10) disclosed by this specification includes a first housing 21 having a terminal accommodating portion 24 into which first terminals 22 are to be accommodated, a second housing 51 including a receptacle 52 into which the first housing 21 is to be accommodated, the receptacle 52 being annularly continuous over an entire periphery, rubber plugs 30 fixed to the first terminals 22 and accommodated inside a rubber plug accommodating portion 25 provided to project rearward from a rear surface 24A of the terminal accommodating portion 24, and a potting agent 60 filled between an inner peripheral surface of the receptacle 52 and an outer peripheral surface of the first housing 21.